RACINE, WI--Feb. 24, 2014: Modine Manufacturing Company , a world leader
in thermal innovation, is developing a series of compact heat exchangers
designed to capture waste heat from the exhaust stream of a diesel engine
and convert this heat into useful power to improve engine efficiency and
reduce CO2 emissions. As part of this development effort, Modine has been
involved in a Department of Energy-sponsored program called SuperTruck and
has provided these heat exchangers to a Cummins-Peterbilt concept vehicle
for comprehensive road testing. During this road testing, the vehicle
achieved 10.7 miles per gallon. The truck also demonstrated a 75 percent
increase in fuel economy in head-to-head testing over a 24-hour time period
compared with a 2009 baseline truck. These results translated to a 43
percent reduction in greenhouse gas emissions and an 86 percent gain in
freight efficiency. The vehicle was on display at a recent event in
Maryland where President Obama announced that work would begin on the next
phase of national greenhouse gas and fuel efficiency requirements for
commercial trucks.

“Fuel economy and the reduction of CO2 emissions are two strong
technology drivers that will create many opportunities for Modine heat
exchanger technology in the future”

The Department of Energy (DOE) initiated the multi-year SuperTruck
program in 2010 with the goal of designing a heavy-duty Class 8 truck that
achieves a 50 percent improvement in overall freight efficiency. The DOE
set the goal of attaining part of the overall efficiency gains from engine
improvements with the remaining gains coming from other vehicle
improvements such as aerodynamics, use of lighter-weight materials, and
reduction of friction in the drive train. Class 8 trucks represent only
about four percent of the on-road vehicles in the United States but are
responsible for almost 20 percent of the country’s on-road fuel
consumption.

The Cummins-Peterbilt collaboration was one of several DOE-selected
partner projects. The objectives of this partnership were to develop and
demonstrate a highly efficient and clean diesel engine, an advanced
Rankine-based waste heat recovery system, an aerodynamic Peterbilt
tractor-trailer combination, and an auxiliary power unit (APU) to reduce
engine idling. Cummins and Peterbilt selected Modine to provide the heat
exchangers for the waste heat recovery system.

The Rankine-based waste heat recovery system operates similarly to a
conventional stationary power plant. A power fluid is boiled using the heat
from the diesel engine exhaust and is sent to a turbine, which converts
this heat into mechanical energy. By recovering this energy from the
exhaust, the diesel engine uses less fuel and CO2 emissions are reduced.
Multiple heat exchangers are required for this system to operate
efficiently. However, unlike a conventional power plant, these heat
exchangers must be miniaturized to fit under the hood and on the chassis of
a conventional Class 8 truck. Lawrence Gabbey, Modine Research Engineering
Section Manager and Program Manager for the SuperTruck program commented,
“Our research engineers utilized Modine’s technology building
blocks to develop highly compact heat exchangers to meet the thermal
management and space requirements of this new challenge. Leveraging the
success of this demonstration program, Modine continues to develop this
waste heat recovery technology in preparation for future commercial
opportunities around the globe in the commercial vehicle and automotive
markets.”

“Fuel economy and the reduction of CO2 emissions are two strong
technology drivers that will create many opportunities for Modine heat
exchanger technology in the future,” noted Jonathan Wattelet,
Modine’s Global Director of Research and Technical Services.
“The SuperTruck public-private partnership sponsored by the
Department of Energy has been an excellent opportunity to leverage our
research in areas where longer-term research is too risky to undertake
alone. Working with engine and commercial vehicle leaders such as Cummins
and Peterbilt has been an outstanding opportunity for Modine to obtain
much-needed engine test cell and road testing experience for our newly
developed heat exchanger technology.”